US 7572670 B2
The invention includes semiconductor packages having a patterned substrate with openings extending therethrough, conductive circuit traces over the substrate and having portions extending over the openings, a semiconductor die over the circuit traces, and a matrix contacting the circuit traces and also contacting the die. The invention also includes methods of forming semiconductor packages. Such methods can include provision of a construction comprising an electrically conductive layer on a masking material. The layer has a first surface facing the masking material and a second surface in opposing relation to the first surface. The masking material is patterned to form openings extending to the first surface of the layer. The layer is then patterned. Subsequently, an integrated circuit die is provided over the second surface of the layer.
1. A method of forming a semiconductor package, comprising:
providing a construction having an electrically-conductive expanse over an insulative-material substrate, the electrically-conductive expanse having a first surface facing the substrate and a second surface in opposing relation to the first surface;
forming a pattern of openings which extend through the substrate to expose regions of the first surface of the electrically-conductive expanse;
plating contact pad material onto the exposed regions of the first surface of the electrically-conductive expanse;
patterning the electrically-conductive expanse into one or more circuit traces, the circuit traces comprising said second surface;
providing a dielectric material in direct contact with the second surface of one or more of the circuit traces; and
providing an integrated circuit die over the dielectric material.
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formation of a patterned mask over the electrically-conductive expanse, the patterned mask covering a first portion of the electrically-conductive expanse while leaving a second portion exposed; and
subjecting said exposed second portion to etching conditions which remove said second portion while leaving the first portion of the expanse remaining over the substrate; the remaining first portion including the one or more circuit traces.
15. The method of
16. The method of
17. The method of
18. The method of
after the plating of the contact pad material and the patterning of the electrically-conductive expanse into the one or more circuit traces, forming a slit extending through the insulative-material substrate; and
forming one or more wire bonds extending from the semiconductor die, through the slit and into electrical contact with the one or more of the contact pads.
19. The method of
the electrically-conductive expanse comprises copper,
the insulative-material substrate comprises a dry film photomask, and
the providing the construction having the electrically-conductive expanse over the insulative-material substrate comprises laminating the dry film photo mask and electrically-conductive expanse to one another.
20. The method of
providing a structure having the polyamide or glass weave core sandwiched between a pair of copper-containing layers; and
removing one of the copper-containing layers to form the construction.
21. The method of
22. The method of
This patent resulted from a divisional of U.S. patent application Ser. No. 10/825,839, filed Apr. 15, 2004, which is hereby incorporated by reference.
The invention pertains to semiconductor packages, and to methods of forming semiconductor packages.
Semiconductor devices (for example, dynamic random access memory (DRAM) devices), are shrinking in the sense that smaller devices are being manufactured that are able to handle larger volumes of data and faster data transfer rates. Semiconductor manufacturers have been moving toward chip-scale packages (CSP) for semiconductor components having a small size and fine pitch wiring.
An exemplary CSP is shown in
The package 10 comprises an interposer 14 utilized to support the semiconductor component 12. The shown interposer comprises a board 15, dielectric (i.e., electrically insulative) material 20 on one side of the board and circuitry 17 on another side of the board. Board 15 can be, for example, a glass weave material. Chip 12 is attached to the board 15 through an adhesive structure 16. The adhesive structure can be, for example, a cured glue, paste, or other polymeric matrix. As another example, the adhesive structure can be a tape. Such tape can have one side adjacent board 15 and an opposing side adjacent integrated circuit die 12, and adhesive can be along both of the opposing sides of the tape.
Dielectric material 20 is patterned to have a plurality of openings extending therethrough to the circuitry 17. Material 20 can comprise, for example, a photomask material, such as, for example, a dry film photomask. If material 20 is a photomask material, the material 20 can be patterned by photolithography. Specifically, the material can be patterned by exposing the material to a pattern of radiation and subsequently utilizing a developing solvent to impart the desired pattern within material 20.
A series of contact pads 30 are provided within the openings in dielectric material 20, and specifically are provided along a surface of circuitry 17 which is exposed within the openings. The contact pads 30 comprise a first conductive material 32 adjacent circuitry 17, and a second conductive material 34 over the first conductive material. Typically, conductive material 32 will be a nickel-containing material, and accordingly can comprise, consist essentially of, or consist of nickel; and material 34 will be a gold-containing material, and accordingly can comprise, consist essentially of, or consist of gold.
The contact pads are utilized for forming electrical contact to circuitry external of the contact pads. Solder balls 36 are shown attached to some of the contact pads, and the solder balls can then be utilized for electrically connecting the solder pads with other circuitry (not shown) external of the contact pads.
A pair of contact pad locations 40 and 42 are shown associated with integrated circuit die 12. Contact pad locations 40 and 42 comprise the nickel-containing material 32 and gold-containing material 34 of contact pads 30, but it is to be understood that contact pad locations 40 and 42 can also comprise other constructions. A pair of wires 44 and 46 are shown extending from contact pad locations 40 and 42, respectively, to a pair of the contact pads 30. The wires connect circuitry associated with integrated circuit die 12 to the circuitry of patterned conductive material 17, and can be referred to as wire bonds.
A slit 50 extends through the interposer 14, and the wires 44 and 46 extend through such slit to make the electrical contact with the contact pads 30.
An encapsulant 60 is provided within the slit 50, and over the wires 44 and 46 to protect the wires of package 10. Similarly, an encapsulant 62 is provided over integrated circuit die 12, adhesive structure 16 and board 15 to provide a protective covering over the semiconductor package.
The shown package of
The package design of
In one aspect, the invention encompasses a semiconductor package having an interposer which contains only a single dielectric support member. The interposer also contains conductive circuit traces contacting the single dielectric support member. The package further includes a semiconductor die electrically connected with at least one of the traces. The traces are between the semiconductor die and the single dielectric support member.
In one aspect, the invention encompasses another semiconductor package. The package includes a patterned substrate having openings extending through it. The package also includes conductive circuit traces over the substrate and having portions extending over the openings. Additionally, the package includes a semiconductor die over the circuit traces, and an adhesive structure (which can also be referred to as an adhesive fastener) touching the circuit traces and touching the die.
In one aspect, the invention encompasses a method of forming a semiconductor package. A construction is provided which has an electrically-conductive expanse over a first dielectric material. The electrically-conductive expanse has a first surface facing the first dielectric material and a second surface in opposing relation to the first surface. A pattern of openings is formed, with the openings extending through the first dielectric material to expose regions of the first surface of the electrically-conductive expanse. Contact pad material is plated onto the exposed regions of the first surface of the electrically-conductive expanse. The electrically-conductive expanse is then patterned into one or more circuit traces. After the electrically-conductive expanse is patterned, a second dielectric material is provided in direct contact with the second surface of the expanse, and an integrated circuit die is provided over the second dielectric material.
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
An exemplary aspect of the invention is described with reference to
The interposer 104 differs from the interposer 14 of
The circuit traces 108 can comprise any suitable electrically conductive material or combination of materials, and in particular aspects will comprise, consist essentially of, or consist of copper.
The support member 106 is patterned to have openings 110 extending therethrough to a surface of the electrically conductive traces 108. Traces 108 can be considered to have first surfaces on the bottom side of the traces in the shown configuration of
Contact pads 30 (only some of which are labeled in the illustration of
The shown openings 110 of
The integrated circuit die 12 has contact pads 40 and 42 associated therewith, and wire bonds 44 and 46 extend from the pads 40 and 42, respectively, to electrically connect with a pair of the contact pads 30.
The adhesive structure 16 utilized to adhere integrated circuit die 12 to interposer 104 can comprise any suitable-material or combination of materials. In some aspects, adhesive structure 16 can be a homogeneous matrix which physically contacts (i.e., touches) the circuit traces 108 and an underside of die 12. The homogeneous matrix can correspond to a cured paste, epoxy, glue etc., and in particular aspects will be a polymeric matrix. Alternatively, the adhesive structure 16 can comprise a tape having opposing sides, with one of the sides being proximate an underside of die 12 and the other sides being proximate circuit traces 108. The tape can have adhesive on both of the opposing sides, with the adhesive on the upper side of the tape being in physical contact with an underside of die 12, and the adhesive on a lower side of the tape being in physical contact with circuit traces 108. The adhesive structure 16 utilized with various aspects of the invention can be, for example, tape adhesive exemplified by Ablestik™ 5405SI™ and DF400™ from Hitachi Cable, or printable B-stage paste exemplified by Cookson™ Staystik 383™, SMM CRM-X2070™, etc.
The interposer 104 has a slit 120 extending therethrough. The wire bonds 44 and 46 extend downwardly from contact pads 40 and 42, through the slit, and then upwardly into openings 110 to contact the contact pads 30 and thereby electrically connect with two of the circuit traces. Although the wire bonds are shown connected to two of the circuit traces, it is to be understood that the wire bonds can connect with more than two or less than two of the circuit traces. Also, although only two wire bonds are shown, it is to be understood that more than two wires bonds or less than two wire bonds can be utilized.
The interposer 104 of
The interposer 104 of the present invention can be advantageous over the interposer 14 of the prior art for numerous reasons. For instance, the interposer 104 can be formed to be much thinner than prior art interposers, which can enable semiconductor packages to be formed which consume less space than the prior art semiconductor packages. Also, the thin interposer of the present invention can be flexible, which can aid in manufacturing and use of the interposers of the present invention. Interposer 104 has a thickness “X” from an uppermost surface of the interposer (specifically an uppermost surface of circuit trace 108 in the shown aspect of the invention) to a lowermost surface (specifically a bottom surface of dielectric 106 in the shown aspect of the invention). In exemplary applications, such thickness can be from about 15 micrometers to about 150 micrometers, with a typical thickness being about 50 micrometers.
The encapsulants 60 and 62 of the prior art package 10 (
The construction of
The material 204 can be referred to as an electrically-conductive expanse. Such electrically-conductive expanse can be homogeneous, as shown, or can comprise multiple different electrically-conductive components. If the material 204 comprises different electrically-conductive components, the components can be in any appropriate orientation, and in particular aspects can be stacked as multiple electrically-conductive layers. Conductive structure 204 can comprise any suitable electrically conductive material, or combination of materials, and in particular aspects will comprise, consist essentially of, or consist of copper. Conductive material 204 is ultimately utilized to form circuit traces, such as, for example, the traces 108 of
Dielectric material 202 can comprise any suitable material or combination of materials, and in some aspects can be referred to as a masking material and/or base material. In particular aspects, dielectric material 202 will comprise, consist essentially of, or consist of a photosensitive mask, such as, for example, a dry film photomask. The material 202 can be 50 micrometer polyimide film, or photomask dry film, for instance. Dielectric material 202 is utilized to form the dielectric support of an interposer of the present invention, such as, for example, the support 106 of
The dielectric material 202 and conductive material 204 can be laminated to one another utilizing conventional methodologies. For instance, if electrically-conductive material 204 comprises a copper foil and dielectric material 202 comprises a dry film photomask, the materials 202 and 204 can be laminated to one another utilizing conventional methodologies for laminating dry film photomasks to metallic foils.
Referring next to
Referring next to
Layers 212 and 214 are electrically-conductive, and can be identical to the layers 32 and 34 described previously with reference to
Layers 212 and 214 can be formed by any suitable method, but electrolytic plating can be a preferred method for forming the layers. Specifically, construction 200 can be immersed in a bath comprising appropriate ions, and an electrical potential can be passed through layer 204 to electrolytically plate layer 212 onto an exposed surface of layer 204. Subsequently, the ions in the bath can be changed, and then layer 214 can be formed by electrolytic plating onto an exposed surface of layer 212. The surface 207 of layer 204 can be protected during the electrolytic plating of layers 212 and 214 to avoid formation of the layers 212 and 214 on the surface 207. Alternatively, or additionally, to the extent that any of materials 212 and 214 form over surface 207, such materials can be moved by polishing and/or other appropriate processing.
Referring next to
Referring next to
Although mask 220 is shown removed in the exemplary processing of
Although the substrate 202 is shown patterned prior to patterning of expanse 204, it is to be understood that the invention encompasses other aspects (not shown) in which expanse 204 is patterned prior to the patterning of expanse 202. In such aspects, material 204 would be patterned prior to formation of contact pads 216 The contact pads 216 may then be formed by other methodology besides electrolytic plating, or, if electrolytic plating is used it may be desirable to form electrically conductive buses extending between the patterned circuit traces and a power source to provide appropriate power to the individual traces for the electrolytic plating operation.
The interposer 250 is identical to the interposer 104 discussed above with reference to
Incorporation of interposer 250 into the construction 100 of
The methodology of
Referring next to
The interposers of the present invention can provide several improvements over prior art interposers. For instance, interposers of the present invention can be fabricated to be relatively thin and low cost, and accordingly can be fabricated to superior design rules. The interposers of the present invention can have relatively few polymers therein, in that there is relatively little dielectric material in interposers of the present invention relative to prior art interposers, which can reduce problems associated with moisture absorption by the polymers and outgassing from the polymers. Interposers of the present invention can be produced in batch, tape or reel form. Further, since interposers of the present invention are relatively thin, they can be used to produce low profile electronics packaging. Also, the current paths in the interposers of the present invention can generate low inductance during operation, due to the thinness of the interposers. The interposers of the present invention can be easily configured with the die pad areas so that input/output devices can be routed to an integrated circuit package that includes the interposers.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.